2 S.E.P Page 2 Konvex AB Feasibility Study - Biomal Concept in Karlskoga SUMMARY More than tons of animal by-products (ABP) are collected and processed yearly in Sweden. About tons, mainly categories 1 and 2, need to be taken care of by combustion. A national action plan to ensure that Sweden has the possibility to take care of ABP in compliance with the EC Regulation 1774/2004 has been formulated by Konvex AB and other industry actors together with the Ministry of Agriculture and the Ministry of Environment. Background data and conclusions from the Action plan have been used as input in this feasibility study. The action plan identified the Biomal TM concept as the main process alternative for taking care of ABP category 1 and 2 in the future. The needed capacity for taking care of normal production of ABP is estimated to tons/year distributed on two plants, one in the middle of Sweden and one in the south of Sweden. The demonstration plant for processing ABP in Karlskoga will have a normal production rate of tons/year with possibility to produce up to tons/year. A suitable location was found at a waste tip near the main road E18 west of Karlskoga centre. The treatment plant will contain an indoors truck receiving station, a raw material hall, two parallel production lines, a container wash, waste water sieving, two Biomal TM -product silos, indoors Biomal TM -product loading, outdoors clean container handling, veterinary area, workshop, offices and changing rooms. The investment cost based on budget tenders including a 10 % marginal is about 8 million. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

4 S.E.P Page 4 Konvex AB Feasibility Study - Biomal Concept in Karlskoga 1. BACKGROUND Approximately 16 million tonnes of animal by-products are produced, rendered and destroyed in Europe each year. When the spread of BSEinfection among cattle became a hot issue a few years ago, a new Regulation - No. 1774/2002 of the European Parliament and of the Council of 3 October was created, laying down health rules concerning animal by-products not intended for human consumption. This regulation stipulates that animal waste such as carcasses and SRM (Specific Risk Material) from slaughterhouses have to be destroyed by combustion. The conventional way of handling these animal by-products is to crush, sterilize, dry and pulverize it after separation of the animal fat. This way of processing the raw material into fat and meat and bone meal is very energy consuming and complicated, as well as costly. An easier, cheaper, more energy effective and environmentally favourable concept was hence developed by the companies Konvex and S.E.P. Scandinavian Energy Project. The concept is called the Biomal - Concept and the fuel, Biomal - fuel. This CO 2 -neutral bio fuel is produced by crushing and grinding the raw material, whole animal carcasses and slaughterhouse byproducts and it has the same energy content as ordinary wood chips. A national action plan to ensure that Sweden has the possibility to take care of Animal By-Products (ABP) in compliance with the EC Regulation 1774/2004 has been formulated by Konvex AB and other industry actors together with the Ministry of Agriculture and the Ministry of Environment. The aim with the plan is to describe how Sweden on long-term shall manage to handle, treat and use the normal production of ABP in Sweden. The action plan has identified the Biomal TM concept as the main process alternative for taking care of ABP category 1 and 2. Many of the background data, technical details and conclusions drawn in the action plan are therefore relevant to this feasibility study and have been used as input. The conclusions from the action plan are to be found in Annex I. Although fuel handling, fuel feeding and co-combustion of the Biomal - fuel have been demonstrated in both short and long-term full-scale tests the fuel production have not yet been properly demonstrated. The Biomal - fuel has so far been produced in temporary installed equipment. The next step in the concept development is to build a demonstration plant for the raw material handling and the production of Biomal TM in Karlskoga where the concept including energy consumption, water consumption emissions to air and water can be quantified and minimized. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

5 S.E.P Page 5 Konvex AB Feasibility Study - Biomal Concept in Karlskoga This feasibility report will determine the basic layout and appropriate location for a Biomal TM preparation plant near Karlskoga. It will further:! describe the process and the main equipment needed! motivate plant production capacity! present a detailed cost plan 2. THE BIOMAL CONCEPT The Biomal concept has been developed step by step during a four-year period. The development work has comprised:! An initial feasibility study regarding suitable preparation steps and combustion technologies.! Development of a fuel feeding system using theoretical studies as well as cold pilot studies.! Short term (weeks) full-scale combustion tests at two different plants using pilot scale crushing and fuel feeding systems.! Installation of a full scale but temporary grinding equipment at an existing rendering plant.! Installation of a fuel handling system at Karlskoga heat and power plant! Long term, 2 firing seasons, environmental and performance studies with co-combustion of Biomal, peat and wood chips. The Biomal TM Concept is schematically described in Figure 1. The Biomal Concept Building Recieving bin Solid fraction Waste water treatment Coarse Chrusher Rotosieve Fine Chrusher Biomal tank Ventilation air to odour control Biomal to local boiler Biomal Water storage tank for external use Figure 1: A schematic description of the Biomal concept Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

6 S.E.P Page 6 Konvex AB Feasibility Study - Biomal Concept in Karlskoga The raw material is delivered by truck in closed containers. The containers are unloaded into the receiving bin and crushed in two steps and pumped into a storage tank. The resulting Biomal fuel is further pumped into a bulk vehicle (alternatively into a local boiler) for further transportation to the boiler. Biomal can be used in conventional boilers for production of heat and power. The introductory basic feasibility study together with full-scale tests showed that a fluidised bed boiler is suitable for this kind of fuel. The fuel is handled in a closed system and pumped into the boiler. Long-term combustion tests in full-scale have also shown very good operating performance and low emission data. For example the NOx emissions are reduced by up to 50%. Figure 2:The Bottom part of a fluidised bed boiler 3. PRODUCTION CAPACITY More than tons animal by-products are collected and processed yearly in Sweden, see Table 1. The animal by-products are divided into 3 categories depending on origin and quality (see Regulation (EC) No 1774/2002). About tons, mainly categories 1 and 2, need to be taken care of by combustion and are interesting as raw material to the Biomal TM -concept. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

7 S.E.P Page 7 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Table 1: The yearly production of some of the collected and processed ABP-streams. Data from Annex I. Raw material and origin category Dead animals Slaugther house byproducts category 1 and Slaugther house byproducts also including SRM from food processing Yearly production Comment ton Destruction by combustion Destruction by combustion Destruction by combustion Slaugther house byproducts Pet food Slaugther house byproducts Bio gas production Food rest products from house hold Bio gas production Rejected food By-products from food processing industry Fodder Bio gas production or destruction 3.1 CAPACITY TODAY The existing capacity is not sufficient for handling the total amount of animal by-products produced in Sweden, especially not for categories 1 and 2. Due to the capacity shortage about 500 ton/week of category 1 and 2 have been processed in Germany and Denmark the last years. Konvex AB, which is the main actor, treat category 1 and 2 ABP in their two plants Stenstorp and Krutmöllan, see Table 2. Both plants produce meat and bone meal and fat. At Stenstorp a complementary line for grinding raw material to Biomal TM -fuel has been installed. The Stenstorp plant has the last two years delivered Biomal TM for the long-term test runs in the Karlskoga heat and power plant 8-9 months/year. In Konvex Vinninga plant category 3 material is treated for biogas production. Some of the Vinninga material has also been used in Karlskoga. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

8 S.E.P Page 8 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Table 2:Capacity today in Konvex plants Krutmöllan Vinninga Stenstorp Localisation Capacity Category Comment Ton/year South of MBM (Maximum Sweden ton category 1 permit South/middle of Sweden South/middle of Sweden until 2006) Crushed to Biogas production and fuel (Biomal) and 2 MBM (during june-sept) and Biomal(temporary installed equipment) 3.2 PLANNED PRODUCTION CAPACITY The estimated normal capacity needed for treating ABP by combustion produced in Sweden is about ton/year (see Annex I) In the action plan it is suggested that, in the future this amount should be taken care of in accordance with the Biomal TM -concept - crushed to Biomal TM -fuel and cocombusted together with ordinary fuels such as wood chips and peat in heat and power plants. To be able to manage break downs and out break of diseases, except extreme situations, a total fuel processing capacity of tons in two preparation plants was suggested in the action plan. Most of the ABP are produced in the south and middle of Sweden and the suggestion is therefore to place one in the middle of Sweden near Karlskoga and one in the south of Sweden near Konvex plant in Krutmöllan. For the Karlskoga plant a normal production rate of ton/year with a capacity of ton/year is suggested. The need for combustion capacity can most probably be met by using existing heat and power plants. Since fluidised bed boilers are commonly used in Sweden there will be many available plants. The boilers in question need to be fluidised bed boilers with a residence time of 2s. above 850 ºC. The plants using Biomal need also to install some new equipment such as receiving station and fuel feeding system for Biomal. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

9 S.E.P Page 9 Konvex AB Feasibility Study - Biomal Concept in Karlskoga 4. LOCALISATION Important criteria to consider when deciding localisation of the planned new demonstration plant using the Biomal TM -concept are 1. The production rate of ABP in Sweden and where it is produced in order to minimize transportation. 2. Combustion capacity using fluidised bed boilers both location and operation time over the year 3. Infrastructure with good transport possibilities Of the tons ABP produced are! produced in the south! produced in the middle! produced in the north of Sweden. Konvex treatment plant in Krutmöllan has capacity to take care of the ABP produced in the south of Sweden. The natural localisation of a new plant is therefore in the middle of Sweden. Karlskoga, situated in the middle of Sweden having a heat and power production plant with two circulating fluidised bed boilers, would therefore be a suitable place to locate the demonstration plant. The Karlskoga heat and power plant has tested Biomal TM for 3 years in one of their boilers with good experience and the plant is already equipped with a receiving station and fuel feeding system for Biomal TM. Based on full scale tests they have decided to continue to co-fire Biomal TM together with peat, wood chips etc. and to expand their Biomal TM -capacity from to tons Biomal TM /year. Karlskoga heat and power plant is also prepared so that it is possible to use Biomal TM in both of their two circulating fluidised bed boilers. Biomal can be combusted in the Karlskoga plant during their firing season october-june. There are several other fluidised bed boilers in the area which could take care of the remaining production capacity. It is however important to find combustion capacity during the summer months. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

10 S.E.P Page 10 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Figure 3: The Karlskoga heat and power plant The localisation of the treatment plant should preferable be in an industrial area with good road standard not too far from the combustion plant. A suitable location about 8 km from the heat and power plant was found at the waste deposit plant Mosserud located west of Karlskoga centre in the Örebro county. The waste tip is owned and operated by Karlskoga Energi och Miljö AB (Karlskoga Energy and Environment AB) which also is the owner of Karlskoga Heat and Power Plant Figure 4: Localisation of the Biomal demonstration plant. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

11 S.E.P Page 11 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Figure 5: A more detailed map of the area near the waste tip. The suggested localisation at the waste tip has good availability for the raw material transports since it is located near the main road E18. The closest dwelling is located 500 m from the waste tip on the other side of the main road. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

13 S.E.P Page 13 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Biomal Storage Tanks Biomal loading Receivingstation Clean containers Production hall Raw material container hall Veterinary Office etc. Veterinary Autopsy office Conference room / office Workshop Cooling room Changingroom etc. Store room Figure 7: Schematic overview of the Biomal production plant in Karlskoga The raw material is delivered in closed containers by truck (30).The trucks are unloaded indoors in the receiving station. The containers are lifted from the trucks by an overhead crane (22) and placed on the floor in the receiving hall. The containers containing carcasses are unloaded into the receiving bins (27) where the carcasses which have to be sampled for BSE or examined by an autopsy can be sorted out. The out-sorted carcasses are transported to a cooling room (++) in the veterinary area for further handling. The raw material continues to the raw material silos (2 and 3) equipped with a transportation screw bottom. Containers containing slaughter house byproducts are unloaded directly into these raw material silos. The raw material is crushed in the coarse crushers (4) situated below the raw material silos and transported via metal detectors (38) to the grinders (16) and pumped into the two product silos (45). The Biomal TM -fuel is pumped into the bulk vehicles (31) for further transportation to the combustion plant. This handling takes place indoors in the Biomal TM -loading station. The emptied raw material containers are, together with their lids, cleaned in the container wash (49) and stored outside under roof in the clean container area before they are moved with a crane on to the container trucks for further transportation. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

14 S.E.P Page 14 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Wash water streams as well as blood and fluent material from the raw material silos are collected and sieved in the rotosieve.(41) The solid fraction is returned into the process stream and the water fraction is transported to a waste water plant. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

16 S.E.P Page 16 Konvex AB Feasibility Study - Biomal Concept in Karlskoga 6. COST ESTIMATION In the LIFE-application there is a cost estimation presented for the demonstration plants. During the work with the lay-out of the plant the estimation has been somewhat revised. In this phase of the project the cost estimation is based on budget tenders for more detailed lay-out than in the application. The costs are also based on a suggested localisation at the Mosserud waste tip in Karlskoga. The costs differs somewhat compared to the application but is still within the same range. The main differences are that the costs for electricity supply, process control and regulation are estimated to be higher in this revised cost estimation compared to the LIFE-application and that the cost for an air treatment device (a bio-filter) and a 10 % uncertainty marginal is included. The cost estimation is based on a basic lay-out and on budget tenders and will be more accurate when the lay-out is more detailed and the tenders are based on detailed constructions. Table 3: Revised cost estimation Budgetary cost estimation Cost estimation in the LIFE application Milj. Milj Main Equipment 2,28 2,00! Receiving Bin! Coarse Crusher! Metal detector incl. Magnet separator! Grinder! Biomal TM -fuel Silos! Waste water treatment Rotosieve! Container wash! Workshop/cranes/Screw feeders etc Electricity supply, process control and regulation 1,63 1,09 Process Supply 0,35 0,38! Process ventilation! Hot watersystem/boiler Air treatment 0,30 Not included Building 2,55 2,72 Road and ground construction, fences 0,22 0,32 Total cost equipment and infrastructure 7,34 6,50 Remaining (10 % marginal for unpredictable costs) 0,73 Not included Total costs including marginal 8,07 6,50 Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

17 S.E.P Page 17 Konvex AB Feasibility Study - Biomal Concept in Karlskoga Annex I. ACTION PLAN FOR ANIMAL BY-PRODUCTS / HANDLINGSPLAN FÖR OMHÄNDERTAGANDE AV ANIMALISKA BIPRODUKTER In regulation EC No 1774/2002 of the European Parliament and of the council of October 2002 the health rules concerning animal by-products, not intended for human consumption are layed down. The ABP regulation includes rules for collection, transport, storage, handling, processing, use and disposal of animal by-products as well as the placing on the market and export and transit in certain specific cases. The member states must make sure that they have appropriate arrangements and enough and suitable infrastructure for taking care of produced animal by-products in compliance with the ABP-regulation. The ministry of Agriculture and the Ministry of Environment decided that an action plan would be formulated together with the industry actors which would describe how Sweden would meet this ABP-regulation. Plants treating ABP must be approved by Swedish Board of Agriculture. They must also have permits in accordance with the Swedish environmental law Miljöbalken. Plants for preparation and processing ABP as well as plants for comdustion of ABP need permits. The farmers, slaughter industry and food industry are responsible to meet the ABP regulation and the Swedish Board of Agriculture has the supervisory responsibility. The aim with the action plan is to describe how Sweden on long-term shall under normal condition manage to handle, treat and use ABP generated in Sweden. Collection and handling of carcasses from cattle, pigs and sheep are granted through agreement between the actors. Bransches, as for example the poultry farming industry, which still has no aggreement are requested to make one. Except the main suggestion in the action plan (the Biomal TM concept) there are two technical alternatives which are still under development. There are also in Sweden a number of approved smaller combustion plants such as straw boilers for use as on the farm. Suggestions and conclusions in the action plan:! The base for this action plan is a developed technical solution for energy recovery of minced meat prepared from ABP by combustion in fluidised bed boilers.! This technology results in great environmental advantages and is also economical favourable since there already exists a lot of suitable fluidised bed boilers which can be used for this purpose.! An investment plan is evaluated for a preparation capacity of and a combustion capacity of tons ABP/year, which will cover the total demand in Sweden under normal disease conditions. Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

18 S.E.P Page 18 Konvex AB Feasibility Study - Biomal Concept in Karlskoga! Provided that the whole volume of category 1 and 2 ABP is enclosed this plan, covering the Swedish need for capacity will be possible to realize.! If decision can be made regarding the described investment plan during summer 2004 and if there are no appeal against the environmental permits the ABP-treatment plans can be in operation at the end of year 2006.! An important factor for achieving an even access to ABP for combustion and desired marginal capacity is that the whole slaughter industry supports this main alternative. The establishment of desired reserve capacity could be facilitated if complementary amounts of processed minced ABP meat could be imported in bulk vehicles from a neighbour state. The regulation in force demands a decision from the government for import of ABP, category 1. It can be practical to, under certain circumstances, authorize the department of agriculture to decide the details in these permissions. Bilateral agreements with a topical neighbour state which regulates import and export could also be included.! At the moment some slaughter houses not connected to Swedish Meats are investigating a separate handling chain including direct combustion for the ABP generated in their plants. Details have not been presented and there is no time table for this solution.! The economical evaluation in the action plan is based on that the processed ABP can be fired in boilers normally using wood chips and peat and that the energy content is positive. It need to be clarified if the regulations regarding combustion of waste (2000/76/EG) is valid for processed ABP or article 12:2 In the ABP-regulation is valid in this case. (For further details see the Action plan written in Swedish.) Solvie Herstad Svärd and Egon Sterngård PM 81/04 Revised by: SB

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